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It is always good to have a good exhaust system on your ATV to maintain its best of performance. To ensure the best performance of your bike, the exhaust should in good condition with the right packing material. If the packing material is damaged, your bike will noise too much and it will stop smooth running.
As the maintenance is important, it is also important to keep the right way and option to repack the exhaust silencer of your ATV. If you find that your bike is getting extra noise and much loud sound is coming out, it will never be able to perform the way it usually did.
This is must be the time when you need to change the packing of the exhaust. Repacking the exhaust silencer is not a difficult task to do but you need to know How to repack your exhaust silencer. But it will surely improve the performance of your bike.
Some people also prefer to have the exhaust wrap for repacking. This item helps in retaining heat in the bike’s exhaust system that enhances the horsepower but reduces the radiant heat of the engine from the biker’s leg.
Table of Contents
- 1 What You Need to Begin
- 2 How to Repack Exhaust Silencer of Your Dirt Bike
- 3 Why you need to replace the exhaust packing
- 4 Final verdict
What You Need to Begin
Silencer of a bike is usually a big tube attached with a smaller tube that presents inside it. Between these two tubes, you get the packing of your exhaust. It is actually a fiberglass product. As the fuel of your bike blows up in the bike’s cylinder, the waves of sound and pressure usually roam through the exhaust and to the cylinder.
The packing of the silencer usually absorbs a large portion of the sound wave. Hot gases of the engine, air moisture and vibration can damage the fiberglass packing of the silencer.
To start the method, you need to have the safety precaution first like the full sleeve shirt, safety glasses, gloves, and the good quality dust mask as you are going to change the packing of the silencer. To change it in your home, you need to have a few necessary tools first:
- New packing material for your silencer
- A wrench set
- High-temperature silicone
- Wire brush
- Masking tape
- Rubber mallet
- Wooden dowel or PVC pipe
- One drill machine
Make sure you buy the right thing
You need to buy only the right 2 stroke muffler packing to repack the silencer of your bike. There are many products available in the market that comes from different brands or manufacturers. Not all the products are up to the mark, you need to deal with only the high-quality packing material that comes with the assurance to last long.
You can buy them online or can pick from a store but don’t forget to read the reviews about the product. You can also take advice from a mechanic or bike expert about the best quality product and they can suggest you with better options. Only the high-quality fiberglass material is ideal for the bike silencer.
You will eventually damage your favorite bike by purchasing low-quality fiberglass. You can buy a 4 stroke exhaust packing for your 2 stroke bike but 2 stroke exhaust packing material will never suit your 4 stroke bike. So, buy the one that made for your bike only.
Take safety precautions
if the experts are doing the repacking process, they better know the right to take necessary precaution for repacking. But if you are doing it yourself, have the necessary safety precaution before repacking the exhaust. If you buy the repack kit from an exhaust packing AutoZone or the OEM 2-stroke muffler packing or the aftermarket pipe, you will get the complete kit. The kit usually comes with all the necessary safety gear that you need.
- Wear a full sleeve dress and wear the rubber gloves that you may find with your kit or buy it separately. Use the dust mask also. No matter how minimum the exposure is, it can come in contact with your eyes or nose.
- Fiberglass is harmful to our health. Fiberglass strands and dust car airborne easily and if it spun in the human lungs if can harm it. Taking proper precaution is always good to save our health. You can also wear safety glasses while working on the bike to repacking the exhaust.
- Never try to it when it is already connected in the bike. Remove it first from the bike and then change the packing and reinstall it again.
How to Repack Exhaust Silencer of Your Dirt Bike
Removing the old exhaust packing
To repack your bike silencer, you need to start by removing the old one first. The process of removing exhaust packing is quite straight forward but only if know the right method. This is best to get to the task done by the help of an experienced and skilled mechanic to remove and install the exhaust packing. If you want to do it by yourself, you can check online the right method and the best procedure. Do it in the right way so that you don’t harm you. Use all the safety features to avoid harming yourself.
Open the bike silencer
You need to open the silencer first. By removing the back cover of your silencer, you can remove it. Also, remove the silencer’s two-end pipes. Then it is the time to remove the silencer’s quiet core. There are six different Allen heads and you need to unscrew them. They located at the diameter of your bike’s silencer.
At first, remove the silencer from your bike. Now hold its cap at the front end and remove the screws that you may find holding the cap in the right place. Keep in mind that some of the bikes have reverts but nit the screws. If your bike contains reverts, you need to use the drill machine to remove them. Take the drill according to the sizes of reverts.
Note that, there are many silencers that come with the screws on its front instead of its back part.
As the screws of the exhaust are removed, you will find the lip on its end cap that you need to remove. It holds the silencer in the right place.
Take the PVC pipe and place the removed silencer on it in a vertical position. You can place it also in a vice to get the right position.
You can drill out the shaft of the rivet. This is quite small in size than the heads. As all the rivets are out, the cap of the front end will freely come out. If your silencer has reverts that you need to remove, you should have enough patience, a sharp drip and also a center punch. The drill should be enough good to break the rivet head, you can end up the process by tapping out the rivets with the center punches. But do not apply an extreme level of force that can bend the housing of the muffler and it can lose its shape. So, for the process, take a good quality drill machine that comes with good power and easy to use.
Now it is the time to pull out the core. You need to remove everything that is present in the old packing material. Take a wire brush and clean the old core with it, check also if there any damage or dirt is present. You can also slide up the first or outer tube of the old packing to take out the inner one. With the wire brush, clean up the inner tube of the packing. If you have the 2 stroke muffler packing it may run quite rich and the little opening of the silencer get blocked often with the sponge coming from the exhaust. So clean it properly to avoid further complications.
As you have removed the older one, you need to work on setting up a new muffler to the silencer. You can check the user manual to remove the muffler. Most of the new age kit comes with all the necessary items that you require to change the muffler.
You need to remove the muffler from your ATV bike, this is not a simple process and for some bike, you need to remove the entire exhaust system of the bike when you are looking for changing the packing only.
Now you need to remove the end cap in a proper way. Various brands and types of bike have different ways to hold up the end cap of the packing. As some of the packings hold up by the rivets some come with the brackets. You need to remove the brackets first. You use the rubber mallet that you have taken as a tool. It will help you to tap on the cap’s sides and to loosen up the cap. Just hold on it and tap gently the bracket mounting until the end cap is loosened up. As the cap is loose, you can pull it to remove.
Now, this is the time to pull out the core tube of the exhaust with the raged packing.
As the core is out, you can easily remove the entire parts of the old packing and you can discard it easily. If you find the steel wool near or around the core tube, clean it properly to ensure that there is no fiberglass left. As the part is clean, you can reinstall or can repack the exhaust silencer. Before reinstalling the new packing, check all the procedures to set it up. You can search online to get the best tutorial of How to repack your exhaust silencer or you can watch the YouTube videos to ensure the process. There is the exhaust packing alternative like still wool or glass that you can use.
Replacing the packing material
As you have removed the old one, you are ready for the exhaust upgrade. You can change it with the old by step by step easy method. Don’t forget to wear the safety gears as you are doing the process like the gloves, mask and full sleeve shirt.
Take the new repacking item and keep it around the tube core
Make sure that the new material for packing comes with the same length and width as the core. As you are keeping the core on the frame of new packing item, you will get an idea about the size. If it doesn’t have the right and direct fitment, you need to cut it to the right size. It should be nearly one and a half inch longer than the exact size of the core. If you want to skip the cutting process, buy the packing material with the cartridge of direct fitment. Measure your old packing or read the size written over the package, to ensure direct fitment.
Now lay out the new packing material and you need to position the tube core at its end. Reinstalling the core with packing is a little bit of difficult. You can use the cartridge style but if you are not using that, your masking tape will come handy for you. Use them for a secure holding of the pack. It will make the process easier for you to fit the tube core and the new packing into the tube. As it receives a huge amount of heat from the bike’s exhaust, the tape will loosen up automatically and it will help the packing to fill properly the tube and then it burns off totally.
You can also roll properly the core into the new packing material. Do it as tightly as possible and it will help you in easy installation. You need to wrap the masking tape in the right way around the new packing material. This step is important to keep the core very tight as per requirement.
Check the ends properly and ensure that there is no obstruction due to the excess of new packing material.
Use the new packing material into the silencer
Push up the core and put the packing material back into your bike’s silencer and use it as the single unit.
Now feed slowly the new packing item into bike’s silencer. When you are doing the method, push down simultaneously on silencer’s core.
As you push it casually, the core will come out from the new packing material and you have to roll the packing material again.
First, you need to ensure that the core is connected properly with the front cap. Place your thumb inside the core and guide the process and push the core into your exhaust.
Reinstalling the end cap
Take a wire brush and clear up the end cap properly with the brush. Ensure that there is no dirt, particles or other things are present.
Now take the high-temperature silicone and apply it to the end cap edges and seal it properly. Before placing back the end cap, you can spend the high-temperature silicone or the RVT sealant. You need to spread it around the end cap. This part is important to make sure that there is a tight seal. It also prevents water from sleeping.
When you are putting up the end cap into the exhaust silencer, you need to make sure first that it correctly fits with the core. Check there are no particles of packing material left. Dirt Bike Exhaust Cleaning is very much important. Rubber millet can help you get snugly the end cap in its right place and also properly flush with bike’s silencer.
Now you need to wipe off if there any excess silicone is present around its edges.
You need to replace now all the six Allen head screws that you have removed previously. Do it gradually and don’t tighten fully before they come in the right place. Gradually tighten up them as they are in the right place.
Now take the wire brush and clean up properly the quiet core. Take a small amount of silicone (high temperature) again on the silencer’s end cap. Do not cover it completely because you need to do it just to dampen up the vibration but don’t seal it. Take only two or three small amount dabs and it will be enough. Now replace your silencer’s quiet core. Take a small amount of silicone again and put it between the pipes (two ends). It is again just to dampen the area. Now you need to replace this end pipe and then the cover. Now tighten up the cover by screwing up back the bolts into its right place.
As your task is finished, you need to put back the exhaust on the bike. After repacking, you will be able to enjoy a tension-free smooth riding. Repacking the silencer is not that much difficult if you follow the right steps. Apart from fiberglass you can buy good quality ceramic muffler packing to repack the silencer but ensure its quality first.
Choose the one that is right for 2-stroke or 4-stroke engine and perfectly compatible with your bike.
Why you need to replace the exhaust packing
Exhaust packing of the bike usually made of fiberglass or ceramic and they never made for lost forever. They degrade over time and you need to upgrade the packing to enjoy smooth riding. If the muffler is damaged it will never able to hold up the airflow and heat of the exhaust. It can absorb the sound waves that coming from the engine combustion as much as possible. The softness of the packing helps the sound waves to dispel between fiberglasses of the exhaust packing. As it wears out or damage, the packing failed to trap more sound waves. Also, exhaust lost the straight shot properly through the packing and it diverted between the can and the core. It ends up by a power loss for your bike. This is the key reason that you need to repack the 2 or 4-stroke muffler packing if it is damaged.
If you are not ready to buy a new packing kit, you can use the homemade muffler packing. You can make it at home with steel wool or fiber but it is good to buy the entire kit from the market because they are properly designed to repack the exhaust of your bike. You can repack your exhaust one in a month. But the mechanics recommend to repack it after ten hours of riding of your bike, which is usually once in a month. But if you find any issue with the packing and damage packing troubling the smooth-riding, you need to replace it with the new one. You can do it yourself or can take the help of a skilled mechanic to reinstall the packing.
A muffler of the exhaust is actually a tubular device and it plays a major role as the exhaust system of your bike is performing differently. It is an integral part of your bike and an acoustic device. It actually functions on the noise and they use primarily to reduce the noise of the bike. But they are not only the noise-reducing device of your bike. Depending on the type of muffler, it also works variously. It can decrease the amplitude of the sound waves and reversely work on the engine. This is the key reason that you will find different sound coming from different bikes. The muffler also helps us to keep the environment less noisy and clean. The engines of the motorbike discharge harmful gases like the carbon-mono-oxide and so the bike can move. These gasses have bad toxins in them can the high-quality packing or muffler of your bike can capture the toxins even before the bike discharge them. So, knowing the right way to repack the muffler is important to keep our environment healthy and our bike in a smooth-riding mode. You can buy the re-packing kit online or can discuss the matter with a skilled mechanic before re-packing it.